Method for producing contact element and / or stator-side busbar

Abstract

The invention relates to a method for producing a contact element (8) and / or a stator-side busbar (26) for a high-voltage connection (10) for producing an electrical connection between a stator (25) having the stator-side busbar (26) and a housing-side joining part (30) of a high-voltage electronic component (35). In order to simplify the production of the contact element (8), a strip made of electrically conductive sheet metal is shaped in such a way that a helical tolerance compensation structure (38) is produced on the contact element (8), which tolerance compensation structure is designed and arranged in such a way that both tolerances along the longitudinal axis (36) of the contact element (8) can be compensated in the installed state by means of the contact element (8), but also tolerances along the longitudinal axis (36) of the contact element (8) can be compensated in the installed state of the contact element (8). An inclined position of the engagement part (30) relative to the contact element (8) can also be compensated.

Description

Technical Field

[0001] The invention relates to a method for producing a contact element and / or a stator-side busbar for a high-voltage connection for producing an electrical connection between a stator having the stator-side busbar and a housing-side connection element of a high-voltage electronic component. Background Art

[0002] From German laid-open patent document DE 10 2019 207 438 A1, an electrically supported turbocharger is known, which has a seal housing, a stator package of an electric motor coupled to the turbocharger, which is connected to the seal housing, and an electronics housing of the electric motor, which is connected to the stator package. From European patent document EP 3 641 068 B1, a plug connector with a coupling plug and a coupling socket is known, wherein the coupling socket comprises an annular socket part and a lamellar rotor cage arranged at least partially inside the annular socket part. Summary of the invention

[0003] The object of the present invention is to simplify the production of contact elements and / or stator-side busbars for a high-voltage connection for producing an electrical connection between a stator with the stator-side busbars and a housing-side connection part of a high-voltage electronic component.

[0004] The object is solved in a method for manufacturing a contact element and / or a busbar on the stator side for a high-voltage interface, the high-voltage interface being used to establish an electrical connection between a stator having a busbar on the stator side and a coupling piece on the housing side of a high-voltage electronic device, the object being solved in the following manner, a strip made of an electrically conductive sheet material is shaped so that a spiral tolerance compensation structure is generated on the contact element, the tolerance compensation structure being implemented and arranged so that not only the tolerance along the longitudinal axis of the contact element can be compensated by the contact element in the installed state, but also the tilted position of the coupling piece relative to the contact element. The spiral tolerance compensation structure is constructed in a substantially cylindrical shell shape at least on its ends that are separated from each other. Between the ends of the tolerance compensation structure that are separated from each other, the spiral tolerance compensation structure can have a reduced or also increased diameter. At least when the contact element is not subjected to load, the spiral tolerance compensation structure can have a substantially constant diameter along its longitudinal axis. In the state of bearing load, especially in the installed state, the configuration of the spiral tolerance compensation structure can be changed so as to achieve the desired tolerance compensation. This significantly simplifies the assembly of the high-voltage interface. The intentionally allowed configuration change of the tolerance compensation structure is caused by the spiral configuration on the one hand. In addition, the contact element is formed by the following material at least in the region of the spiral tolerance compensation structure, and the material can be elastically deformed in a limited manner. The spiral for establishing the spiral tolerance compensation structure can include a spiral cut (Helixschnitt) in the tolerance compensation structure of a basically cylindrical shell shape. But the spiral can also include more than one spiral cut. The tolerance compensation capacity can be improved. But the configuration of the tolerance compensation structure with multiple spiral cuts is also more expensive in manufacturing. The electrical connection is called a high-voltage interface, and the electrical connection can be operated by an alternating voltage of thirty volts to one thousand volts or by a direct voltage of sixty volts to one thousand five hundred volts. Here, high safety requirements, especially in terms of touch protection, are guaranteed. The strip made of conductive sheet material preferably has a substantially elongated rectangular configuration, which is a primary product when manufacturing the contact element. The strip made of an electrically conductive sheet metal is preferably produced cost-effectively, for example by punching. The strip made of an electrically conductive sheet metal can be shaped relatively cost-effectively so that the desired helical tolerance compensation structure results in the contact element.

[0005] A preferred embodiment of the method is characterized in that a strip made of an electrically conductive sheet is punched out in order to produce the basic shape of the contact element in the electrically conductive sheet. This makes it possible to advantageously produce a large number of strips in a single method step by means of a suitable punching device.

[0006] A further preferred embodiment of the method is characterized in that the strip made of the conductive sheet is provided with at least one longitudinal slit. The longitudinal slit is preferably produced in the conductive sheet by the punching process described above. The longitudinal slit is preferably arranged centrally in the sheet-shaped strip. The longitudinal slit in the middle of the sheet-shaped strip imparts sufficient elasticity to the finished contact element in order to establish the desired tolerance compensation function.

[0007] Another preferred embodiment of the method is characterized in that the strip made of the electrically conductive sheet metal is bent into a circle several times around the longitudinal axis of the contact element, thereby resulting in a substantially cylindrical jacket-shaped configuration of the bent sheet metal, which has the desired helical tolerance compensation structure.

[0008] Another preferred embodiment of the method is characterized in that the strip made of conductive sheet material is bent (abgewinkelt) on the end facing the joint before being bent into a circle so that after being bent into a circle, a configuration of a circular ring piece with a through hole is obtained on the end. The circular ring piece with a through hole is used to establish a bolt joint, on which the end of the contact element facing the joint can be fixed to the joint in a simple way conductively and very stably (for example, by means of bolts). Particularly advantageously, the circular ring piece is not completely closed in the circumferential direction. This significantly simplifies the manufacturing. For example, it is sufficient to bend only a relatively large section, which is used to establish the bolt joint. It is also possible and advantageous in some cases to bend multiple sections on the end of the strip made of conductive sheet material facing the joint, which sections are used to establish the bolt joint.

[0009] Another preferred embodiment of the method is characterized in that the strip made of conductive sheet material is formed into a multifunctional sleeve when it is bent into a circle on the end facing away from the joint. The multifunctional sleeve basically has the configuration of a straight cylindrical shell. The multifunctional sleeve is preferably connected to the contact element in one piece. But it is also possible that the multifunctional sleeve is connected to the contact element in another way, such as material locking. The conductive connection of the multifunctional sleeve to the busbar is preferably carried out in a material locking manner. But according to the embodiment, the multifunctional sleeve can also be connected to the busbar in another way, such as force locking, shape locking or also in one piece. The multifunctional sleeve is additionally implemented in addition to its conductive function at least one other function on the high-voltage interface. This other function preferably includes at least one sealing function. In addition, the multifunctional sleeve is also advantageously used to position the tolerance compensation structure constructed on the contact element relative to the joint so that the conductive connection between the end of the contact element facing the joint and the joint is preferably manufactured by means of bolts.

[0010] Another preferred embodiment of the method is characterized in that the busbar is provided with a stretching at a first end, which stretching is a multifunctional sleeve, which is assigned to the end of the contact element facing away from the joint. The stretching is advantageously realized on the busbar by forming, in particular by deep drawing. The multifunctional sleeve on the busbar is advantageously implemented identically or similarly to the multifunctional sleeve on the contact element described above. The connection between the multifunctional sleeve and the contact element is preferably implemented in a material-locking manner. The material-locking connection is produced, for example, by welding.

[0011] A further preferred embodiment of the method is characterized in that the busbar is provided with a crimping geometry at the second end. The crimping geometry simplifies the joining of the stator conductor to the busbar. The crimping geometry at the second end of the busbar is preferably produced by forming.

[0012] A further preferred embodiment of the method is characterized in that the crimping geometry has two semicircularly curved wings which are connected to one another in a materially bonded manner at their ends facing one another. This further simplifies the production of the high-voltage connection.

[0013] In the case of a contact element and / or busbar manufactured according to the method described above, the above-mentioned tasks are solved alternatively or additionally in that the contact element, in addition to the helical tolerance compensation structure, additionally has a high current conduction function and a screw surface on its end facing the connection part. The contact element claimed can be manufactured simply and cost-effectively. In addition, the tolerance compensation structure enables compensation of tolerances that are unavoidable or can only be avoided at great expense in a simple and effective manner when the contact element is installed. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying drawings show:

[0015] Figure 1 Longitudinal section through a high-voltage connection for producing an electrical connection between a stator and a connection piece on the housing side of an air supply device;

[0016] Figure 2 A perspective view of an air supply device having a housing, the housing comprising a high-pressure connection having three contact elements;

[0017] Figure 3 a perspective view of a contact element which is electrically conductively connected at one end to an end of a busbar;

[0018] Figure 4 Figure 3 A three-dimensional illustration of a contact element in a non-loaded or unassembled state;

[0019] Figure 5 Figure 4The contact element is in a load-bearing state, which can occur in an assembled state, for example;

[0020] Figure 6 A perspective view of a contact unit fixed to a thermostatic sleeve, the contact unit having three contact elements;

[0021] Figure 7 Figure 6 A perspective view of the contact unit in FIG. 1 as viewed from the rear side;

[0022] Figure 8 a perspective view of a joining unit having three support columns for three contact elements;

[0023] Fig. 9 a perspective view of a combined plug unit with a plug seal;

[0024] Fig.10 A perspective view of a strip provided with longitudinal slits, the strip being made of an electrically conductive sheet material for producing a contact element with a helical tolerance compensation structure;

[0025] Fig.11 Fig.10 A plate-shaped strip bent into a circle, wherein the plate-shaped strip has a desired spiral tolerance compensation structure;

[0026] Figures 12 to 14 How can the contact element 8 Fig.11 Three embodiments of bolt joints on the right end of the embodiment;

[0027] Fig.15 a perspective view of a busbar having a multi-function sleeve on a first end and a crimping geometry on a second end; and

[0028] Fig.16 Fig.15 A perspective view of a busbar in a circuit diagram, wherein the busbar has a multifunctional sleeve fixed thereto. Fig.11 The contact elements in. DETAILED DESCRIPTION

[0029] exist Figure 2 The air supply device 1 is shown in perspective in FIG. The air supply device 1 is also called an air compressor and is used in a mobile fuel cell system to provide compressed air. The mobile fuel cell system is in turn used in a vehicle equipped with a fuel cell system to provide electrical energy, which is converted into drive energy for the vehicle, for example, by an electric motor.

[0030] The air supply device 1 comprises a multi-part housing 2 having an air connection 3, via which the air is supplied, and an air connection 4, via which the compressed air is discharged. To compress the air, the air supply device 1 comprises, for example, a compressor wheel which can rotate inside a compressor volute.

[0031] The compressor wheel is driven by an electric motor, optionally with assistance from a turbine wheel, which is arranged in housing 2. The electric motor comprises a rotor which can rotate within a stator.

[0032] The stator of the electric motor comprises a current coupling device 5, through which a three-phase alternating current is supplied to the stator. The current coupling device 5 is connected to a control coupling device 6 via a connecting device, which comprises three elongated contact elements 7, 8, 9. The contact elements 7, 8, 9 are used to establish a high-voltage interface 10 between the stator and the high-voltage electronics.

[0033] The high-voltage electronics include a converter. The control connection device 6 is combined, for example, with a cable outlet which, as indicated by the three output cables shown, is connected to a separately arranged and Figure 2 However, the inverter can also be integrated into the housing 2 of the air supply device 1.

[0034] exist Figure 1 8 shows a high-pressure connection 10 in a longitudinal section through the contact element 8. The housing 2 of the air supply device comprises two housing bodies 11, 12. In addition, the housing body 11 is used to receive an electric drive for the air supply device. The housing body 12 is used, for example, to rotatably receive an impeller, in particular a compressor impeller. The compressor impeller is driven by the electric drive in the air supply device.

[0035] Depend on Figure 1 , 6 The overview of Figures 1 and 7 shows that a total of three contact elements 7, 8, 9 in the electrical contact unit 14 are each connected to a busbar 26. The electrical contact unit 14 is mounted on a temperature control sleeve 24, which surrounds the stator component 20 in the housing body 11 and has a stator component 20 at Figure 1 25 . Since the temperature control jacket 24 is mainly used to cool the stator 25 , it is also referred to as cooling jacket 24 .

[0036] The stator 25 includes a stator winding and a coil head, from which the stator wires originate. Figure 12 , in a manner not visible in the section shown in FIG. 2 , the busbar 26 is electrically conductively bonded to its radially inner end. The contact element 8 electrically conductively connects the busbar 26 to a bonding piece 30 of a high-voltage electronic component 35, which is likewise only designated by a reference numeral. The high-voltage electronic component 35 comprises a current converter.

[0037] exist Figure 3 Only the busbar 26 together with the contact element 8 fixed thereto is shown in perspective. Figure 3 At the upper end of the busbar 26 in the embodiment, the contact element 8 is connected to the busbar 26 by a material connection. Figure 3 A crimping sleeve 45 is formed on the lower end of the busbar 26 in FIG. The crimping sleeve 45 is used for electrical connection of a stator conductor (not shown).

[0038] The contact element 8 has a multifunctional sleeve 16 at its end facing the busbar 26. The multifunctional sleeve 16 is provided with a Figure 3 The left end in FIG. 1 is electrically conductively connected to the busbar 26 in a materially bonded manner, preferably by welding.

[0039] exist Figure 4 As can be seen from the three-dimensional view of the contact element 8, Figure 3 On the right end in FIG. 1 , there is an annular disk 28 with a through hole 29 . At the same end, the contact element 8 has a first conical section 41 . The second conical section 42 is formed by the contact element 8 between the helical tolerance compensation structure 38 and the multifunctional sleeve 16 .

[0040] exist Figure 4 and 5 1, it is explained how the contact element 8 deforms in the region of the helical tolerance compensation structure 38 during assembly when a load acts on the contact element 8 having the tolerance compensation structure 38. Such loads occur, for example, when tolerances along the longitudinal axis 36 need to be compensated or when an inclined position of the coupling part 30 also needs to be compensated. Such tolerances cannot be avoided, depending on the type of production, or can only be avoided with increased effort.

[0041] exist Figure 3 , a view of the longitudinal axis 36 which is not visible there and is only used for illustration is shown. Figure 3 It can be seen in FIG. 8 that the contact element 8 is arranged with its longitudinal axis 36 perpendicular to the longitudinal extension of the busbar 26 .

[0042] exist Figure 1 As can be seen in FIG. 8 , the contact element 8 is Figure 1The right end of the contact element 8 is fixed to the joint part 30 by means of a screw 31. The screw head of the screw 31 is arranged inside the tolerance compensation structure 38. The screw shank of the screw 31 is screwed into a corresponding threaded blind hole in the joint part 30. This ensures a stable and electrically conductive permanent connection between the contact element 8 and the joint part 30 in a simple manner.

[0043] The helical tolerance compensation structure 38 of the contact element 8 is arranged inside the support column 40. There is sufficient play between the support column 40 and the tolerance compensation structure 38 to enable movement and / or configuration changes of the contact element 8 in the region of the tolerance compensation structure 38. Such configuration changes are for example Figure 4 and 5 An overview of the results is obtained.

[0044] A plug seal 18, an inner seal 21 and an outer seal 22 are provided for sealing the high-pressure connection 10. The plug seal 18 is pressed into the receiving space 17 by means of a plug of a combined plug unit 23, which is provided for this purpose in the multifunctional sleeve 16. The plug of the combined plug unit 23 is used in particular to support the plug seal 18 in the receiving space 17 of the multifunctional sleeve 16 in such a way that the plug seal 18 cannot be deformed undesirably.

[0045] The multifunctional sleeve 16 has a radially outer bearing section 19 on which an inner seal 21 is arranged. The inner seal 21 is designed as an inner single seal and is arranged in an annular space which is delimited radially inwardly by the multifunctional sleeve 16. The annular space is delimited radially outwardly and in both axial directions by the electrical contact unit 14.

[0046] An outer seal 22 is arranged radially outside the inner seal 21. The outer seal 22 is designed as an outer integrated seal and is arranged in an annular space which is delimited radially on the inside by the electrical contact unit 14 and radially on the outside by the housing body 11.

[0047] The conical sections 41 and 42 enable a damage-free assembly of the inner seal 21 onto the multifunctional sleeve 16. The third conical section 43 enables a damage-free assembly of the plug seal 18 to the combined plug unit 23.

[0048] The sealing shoulder 27 in the housing body 11 ensures that the outer seal 22 remains in its desired position.

[0049] exist Figure 6 and 72 shows how the outer seal 22, which is designed as an outer integrated seal, is mounted together with the three contact elements 7, 8, 9 and the sensor connection point 48 on the electrical contact unit 14. The electrical contact unit 14 is in turn fastened to the temperature control sleeve 24. Furthermore, screw points are provided at which the electrical contact unit 14 is fastened to the housing 2.

[0050] exist Figure 8 , for example, shows a joining unit 50 which has a total of three support columns 40 for three contact elements.

[0051] exist Fig. 9 1 and 2 show in perspective the plug seal 18 combined with the combined plug unit 23. The combined plug seal 18 comprises a single plug seal for each contact element.

[0052] exist Fig.10 The strip 61 with longitudinal slits 62 is shown in perspective, and is made of an electrically conductive sheet metal 60. The strip 61 can be produced very simply in a stamping process with low production costs and in large quantities. The slit strip 61 can then be bent into a round shape by means of simple bending techniques and the strip can be bent in a round shape. Fig.11 The right end portion is formed in the middle.

[0053] exist Fig.11 The spiral tolerance compensation structure 38 shown in FIG. 1 is produced on the contact element 8 by winding a strip 61 provided with a longitudinal slit 62 from a sheet metal 60 several times around its own axis. The longitudinal slit 62 in the middle of the sheet metal strip 61 imparts sufficient elasticity to the finished contact element 8 with the tolerance compensation structure 38 in order to achieve the desired tolerance compensation.

[0054] In order to produce the circular ring 28, which is used to create the screwing surface, the front region of the angled plate-shaped strip is either bent completely or in a plurality of sections, as in Fig.12 , 13 As shown in 14.

[0055] Fig.12 A large section 64 is shown, which extends over almost the entire circumference at the end of the contact element 8 in order to create a circular ring 28 with a through-opening 29. Fig.13 In FIG. 8 , the three segments 67 , 68 , 69 are arranged evenly distributed over the circumference at the end of the contact element 8 . Fig.14 2 shows a circular ring disk 28 with a through-opening 29 , which has two oppositely disposed sections 65 , 66 .

[0056] exist Fig.15 and 16, it is shown that the multifunctional sleeve 16 is moved onto the contact element 8 into the busbar 26, which together with the plug seal 18, the inner seal 21 and the outer seal 22 serves to seal the high-pressure connection 10. This also offers the advantage that the contact element 8 can be designed more simply and thus more cost-effectively.

[0057] The multifunctional bushing 16 is implemented as a busbar 26 in Fig.15 The left end of the Fig.16 70 in the right end of the busbar 26. A crimping geometry 71 is formed at the other end of the busbar 26. The crimping geometry 71 comprises two wings 72, 73 which are bent to create a crimp sleeve and are welded at their ends facing each other by a weld seam 74. Fig.16 The busbar 26 is shown in combination with the contact element 8. The connection between the multifunctional sleeve 16 and the contact element 8 is realized, for example, by welding.

Claims

1. A method for producing a contact element (8) for a high-voltage connection (10) and / or a stator-side busbar (26), the high-voltage connection being used to establish an electrical connection between a stator (25) having the stator-side busbar (26) and a housing-side connection element (30) of a high-voltage electronic component (35), characterized in that: The strip (61) made of an electrically conductive sheet material (60) is shaped so as to produce a spiral tolerance compensation structure (38) on the contact element (8), the tolerance compensation structure being implemented and arranged so that, in the installed state, the contact element (8) can compensate not only for tolerances along the longitudinal axis (36) of the contact element (8) but also for an inclined position of the coupling part (30) relative to the contact element (8).

2. The method according to claim 1, characterized in that The strip (61) made of the electrically conductive sheet (60) is punched out in order to produce the basic shape of the contact element (8) in the electrically conductive sheet (60).

3. The method according to any one of the preceding claims, characterized in that The strip (61) made of the conductive sheet material (60) is provided with at least one longitudinal slit (62).

4. The method according to any one of the preceding claims, characterized in that The strip (61) made of the electrically conductive sheet metal (60) is bent into a circular shape several times around the longitudinal axis (36) of the contact element (8).

5. The method according to claim 4, characterized in that The strip (61) made of the conductive sheet (60) is bent at the end facing the joining part (30) before being bent into a circle, so that after being bent into a circle, a circular ring (28) with a through hole (29) is obtained at this end.

6. The method according to claim 4 or 5, characterized in that: The strip (61) made of the electrically conductive sheet material (60) is formed into a multifunctional sleeve (16) at the end facing away from the connection element (30) when it is bent into a round shape.

7. The method according to claim 4 or 5, characterized in that: The busbar (26) is provided at a first end with an extension (70) which creates a multifunctional sleeve (16) which is associated with the end of the contact element (8) facing away from the connection piece (40).

8. The method according to any one of the preceding claims, characterized in that The busbar (26) is provided with a crimping geometry (71) at a second end.

9. The method according to claim 8, characterized in that The crimping geometry (71) has two semicircularly curved wings (72, 73) which are connected to one another in a materially bonded manner at their ends facing one another.

10. A contact element (8) and / or a busbar (26) produced according to the method as claimed in any one of the preceding claims, characterized in that: In addition to the helical tolerance compensation structure (38), the contact element (8) also has a high-current conducting function and a screw surface at its end facing the joining part (30).

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